$1,200 to cut 14 pieces???

[stevem]

Hello, I'm building an Avro Vulcan cockpit, and I am seeking to have the 7 plexiglass windows and 7 frames cut (from PVC high-density foam board).

I have the CAD drawings, and I asked a local plastics firm for a quote to cut the pieces. $1,200!!! Wow.

Am I off-base with thinking that this should be around $200?

Does anyone have ideas on how I can get these pieces cut for around $200 or less?

Thank you.

[cmdr114b]

I paid £220.00 for all the 5mm thick Perspex for my A320 cockpit but this was not cut to shape.
it's not difficult to cut, just print out your templates from your CAD drawings, draw round them, cut with a jig saw or Dremel. Having said all that, the company I used will cut and polish the edges but at a cost.
http://www.perspexsheet.uk/perspex-clear/
John

[stevem]

Thanks, cmdr114b. My original plan was to jigsaw the pieces, anyway... but, I'd rather outsource them, if the price is right.

Pics of your A320 cockpit?

Here's a photo of the cardboard mockup, and the first two metal fuselage panels that I've built.

Any other ideas regarding getting plastic cut for cheap? Thanks!

[cmdr114b]

I looked at having my windows laser cut but the prices quoted where just too expensive.
It took me a couple of days to cut the perspex, I started using a Dremel which does work but was very slow.
In the end I used my table saw to cut close to the lines then finished using an air sander.
If you want polished edges then start with 80 Grit paper and keep increasing the grit to say 1200 Grit until you get the finish you want.
Finally polish with a rough polishing compound and then T-Cut to get the final gloss.

For me I have all hidden edges so edge finish was less important.

[cmdr114b]

Sorry I should have said, great job on your cockpit, it should look very realistic when its done.

I have seen the real Vulcan several times in the past and every time it took my breath away, it was a fantastic aircraft.
Its a shame that the last Vulcan ( XH558 ) no longer flies.
John

[blueskydriver]

Why not buy a cheap 9-10" band saw and cut them yourself?

First, you use the jigsaw to cut about 1" from the actual finish cutline, then use band saw to cut the finish cutline. The key is to use masking tape on both sides of the material where any cuts will be made, as this prevents cracking/splintering. Also, whatever you use to cut with go slowly with the rpms, faster rpms produce heat and causes melting.

I did my B737 windows this way...

John

[stevem]

John, that A320 is bad a**!!! Nice work!

I do have a quality jigsaw and scroll saw, so I'll probably use those. It's just more time, when I should be forming the fuselage shell. I know... welcome to sim building! : )

And, blueskydriver, thanks for the tips on cutting cleanly.

The most-often question I receive is, "Why a Vulcan?" My answer: "Why not?"

Seriously, it's a way-cool plane. I remember at age 10 (1982) in Chicago, Illinois, at the Lakefront Air And Water Show, when the RAF brought a Vulcan to the air display. I'll never forget that dark, delta shape, flying low over the lake, and that sound. And, of course, the Vulcan was in the movie Thunderball, so that's just cool.

A few more pics of the cardboard mockup phase, and some early prototype work on a switch panel and warning light fabrication...

[Geremy Britton]

Love the work on the Vulcan cockpit. I must confess one of my all-time favourite aircraft!

[stevem]

Pics of the windshield frame coming together.